Portable device and method for production control and quality control

ABSTRACT

A system and method is for production control, and comprises an electronic device, and one or more network connectors associated with the electronic device configured to connect to a server computer. The server computer contains a database of one or more work instructions that are downloadable to the electronic device through the network connector. The one or more work instructions are configured to provide operation instructions for one or more tools and the one or more network connectors are further configured to provide work instructions to the one or more tools.

RELATED APPLICATION INFORMATION

This application is a continuation patent application which claimspriority from Nonprovisional patent application Ser. No. 14/872,363,entitled “Portable Device And Method For Production Control And QualityControl”, filed on Oct. 1, 2015, which claims priority from ProvisionalPatent Application Ser. No. 62/059,005, entitled “Portable Device AndMethod For Production Control And Quality Control”, filed Oct. 2, 2014,the contents of which are hereby incorporated by inference in itsentirety.

FIELD OF THE INVENTION

The invention relates to a portable device and method for productioncontrol and quality control. Specifically, the system and methodprovides a portable device and method for production control and qualitycontrol, giving the operator up to date work instructions and forcollecting results data from industrial tools.

SUMMARY OF THE INVENTION

In accord with a preferred embodiment of the invention, a system forproduction control comprises: a portable electronic device; one or morenetwork connectors associated with the portable device configured toconnect to a server computer, the server computer containing a databaseof one or more work instructions that are downloadable to the portableelectronic device through the one or more network connectors, the one ormore work instructions configured to provide operation instructions forone or more tools; and the one or more network connectors furtherconfigured to provide work instructions to the one or more tools.

In accord with another preferred embodiment of the invention, a methodfor production control comprises: connecting a portable electronicdevice to a server computer using one or more network connectorsassociated with the portable device, the server computer containing adatabase of one or more work instructions that are downloadable to theportable electronic device through the one or more network connectors;and according to the one or more work instructions, providing operationinstructions for one or more tools.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic overview of network platform that may be usedin one embodiment of a production control and quality control system;

FIG. 2 is a diagram illustrating selected components of the server ofthe embodiment of FIG. 1;

FIG. 3 is a diagram illustrating selected components of one or more ofthe electronic devices according to the embodiment of FIG. 1; and

FIG. 4 is a flow diagram describing steps executed by the softwareprogram and client application according to the embodiment of FIGS. 2and 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purpose of illustrating the invention, there is shown in theaccompanying drawings several embodiments of the invention. However, itshould be understood by those of ordinary skill in the art that theinvention is not limited to the precise arrangements andinstrumentalities shown therein and described below.

With reference to FIG. 1, a diagrammatic overview of network platformthat may be used in one embodiment of a portable device and method forproduction control and quality control. In one embodiment, a servercomputer 70 may comprise one or more complex instruction set computers(CISCs) or one or more reduced instruction set computers (RISCs). Theserver 70 may comprise a network connector that connects the servercomputer to a wide area network (WAN) 100. The WAN may comprise, forexample, a virtual private network over the Internet.

In one embodiment, the Internet 100 may thus provide for secureconnections with the server computer 70 to electronic devices connectedto the Internet 100. The connection can best be covered under theumbrella of the Internet of Things (IoT). Said devices may include, byway of example and not by way of limitation, one or more personal mobileelectronic devices 42 connected to Internet 100 via Wi-Fi or a cellularnetwork 50, which may comprise a digital 2G, 3G, 4G, WMAX, near fieldcommunication (NFC), light emitting diode (LED), or other cellularnetwork 50. A satellite network 54 may also or alternatively be used toconnect with the server computer 70. In this regard, each personalmobile electronic device 42 may include, by way of example and not byway of limitation, a personal mobile communicator or cellular phone,smart phone, tablet, two-in-one, or any personal digital communicator.

In addition, in one embodiment, the mobile devices 42 may alternativelycommunicate with the Internet 100 via cellular towers 50 located in thecellular network. In the case of a mobile device 42 that may comprise asatellite enabled device, such as a satellite phone, communication withthe Internet 100 may occur via a satellite 54.

However, in one embodiment, one or more of the devices 42 may includethe TEKFLEX TF300i, TF200 or TF100 hand held device currently availablefrom I and R Partners, Inc. of Madison, TN. In one embodiment, theTekFlex hand held device is able to connect to an industrial tool (62 inFIG. 1) through a Bluetooth interface 63.

The handheld device 42 may thus provide the operator downloaded up todate work instructions 123. Further, the handheld device 42 may collectresults data from the industrial tool 62. Further, the handheld device42 also may control the industrial tool 62. The downloaded workinstructions 123 may also include settings for the tool 62. Also, thework instructions may include 123 sequences for testing the industrialtool 62, and collecting results data, which may all be done through thehandheld device 42.

Any of the above-described devices or tools may be Wi-Fi and/orBluetooth enabled with a Wi-Fi, 4G, 3G, wireless, near fieldcommunication (NFC) and/or Bluetooth radio transceiver installed orintegrated into the device as recognized by those of skill in the art.In this regard, a Wi-Fi hub 90 may optionally be used with any of suchwireless-enabled devices to connected and communicate data 122, 123 overthe Internet 100.

Further connected to the network may be one or more personal computingdevices 60. Each personal computing device 60 may comprise, by way ofexample, a personal computer, a notebook computer, a tablet, a laptopcomputer, smart television (smart TV), Roku® device, or the like.

With reference to FIG. 2, a diagram illustrating selected components ofthe server 70 of the embodiment of FIG. 1 is shown. In one embodiment,the server 70 may comprise one or more sets of computer instructions, orsoftware, that may comprise an on-call software program 76. Server 70may further comprise one or more storage devices 72 for storing one ormore databases 302. The database may include records 304 associated withwork instructions 123 for industrial tools 62. Each set of workinstructions (WI) may be stored in one or more WI fields in each record304 of the database 302.

In the embodiment of FIG. 2, each database record 304 may be indexed bya work instruction ID. The work instruction ID may be tied to the typeof tool 62, and the job to be performed by the tool 62 and the operator12. Optionally, operator names may be stored in the database records.Further, an error condition field may store whether there was an errorin the operation of the tool 62. The error condition may store moregranular information, such as the type of error condition (e.g., normal,over torque, tool operation error, etc.), operator, and procedure inwhich the error occurred. Finally, corrective measures that may beapplied to the tool 62 through the device 42 may be stored, thusproviding a feedback mechanism to correct the errors for the tool 62.The device 42 may contain, for example a keyboard input, on screenkeyboard input, voice recognition software, touch screen, or any othertypes of input devices known to those skilled in the art capable ofreceiving input from an operator to define the error and/or to suggestcorrective measures.

With reference to FIG. 3, selected components of one or more of theportable devices 42 are shown according to the embodiment of FIG. 1. Inone embodiment, devices 42 may have differing operation systems, andother hardware components, the devices 42 typically have certain commonfeatures. While some form of the components of FIG. 3 typically mayexist in all the different types of devices 42 of FIG. 1, the universalcomponents will be described with respect to devices 42 in FIG. 3, withthose skilled in the art recognizing that these components may be incommon with all types of devices 42 referenced and described above withrespect to FIG. 1. By way of example, and not by way of limitation,device 42 may include a processor 44, and an operating system configuredto execute on the processor. A memory storage device 250 may further beincluded to store both application code for applications, andapplication data. One of those applications may comprise a clientportion of the client application 200 that executes on devices 42. Ofcourse, the operation, look and feel of the client application 200 mayor may not have a different configuration depending on whether thedevice 42 is a smart phone, tablet, or computer 60, TEKFLEXTF300i/TF200/TF100, or other type of device.

With reference to FIG. 4, a flow diagram describing steps executed bythe software program 76 and client application 200 according to theembodiment of FIGS. 2 and 3 is shown. It should be recognized by thoseof skill in the art that some steps may be performed by the clientapplication 200 locally, and the server application 76, depending onsharing of resources, communication bandwidth, and other factors forapplication efficiency. The steps will be described with thisunderstanding.

In step 402, the user (12 in FIG. 1) may login with their user name andpassword on the portable device 42, whereby the database record for theparticular work instruction 123 is updated to reflect the user 12 thatis operating the tool 62. In step 404, the portable device 404 mayinterface with the server 72 to receive and update work instructions(WI) 123 on the portable device 62, which may include, for exampleassembly schedules or operation limits of the tool, such as upper andlower control limits. For example, the server may download bothinstructions for the user 12 and instructions to the tool 62. In step406, the tool may then automatically be configured to operate accordingto the WI 123. For example, a compressor might be configured to providea certain amount of torque to an air-wrench so the operator can use theair wrench to tighten lug nuts, or the like. Normally, the compressors'pressure is controlled by a dial or knob that is turned to adjust theholding tank's pressure. In embodiment, instead, a servo controlledactuator may be used to turn the shaft of the knob. The servo motor ispowered by the compressor and a small receiver and circuit may controlthe stepper. This embodiment may be easily retrofittable to existingpumps in the field. In another embodiment, the pressure may becontrolled by incorporation of a soft-switch that is incorporated withinthe compressor housing. The WI provides instructions to both the userand the tool to complete the task.

In step 408, in one embodiment, the operator has an option to overridethe WI 123 with procedures developed through the portable device 42. Forexample, pressure settings from a tool 62 comprising ahydraulic/pneumatic pump may be set through the device 42 comprising aTEKFLEX TF300i/TF200/TF100 to control a servo actuator. If so, then instep 410, the portable device may be used to receive modifications tothe WI 123. However, to keep integrity within the error checking methodof the system, the portable device may send the modified instructionsback to the server 72 to be stored in the records 304 of the database302 in case the modified instructions do cause error in operation of thetool 62, step 412. Those modified instructions may also includinginstructions that make sure the operator is operating the tool withinspecifications.

In step 414, the tool 62 is operated by the portable device 42 accordingto the WI 123. During operation, performance data during operation ofthe tool 62 may be collected by the portable device 42 and transmittedto the server 76 for storage in records 304 of database 302, andtransmitted to other computer devices 60 for analysis, performance graphplotting, or other measurements on screen in real time.

In summary, the handheld device 42 may control tools 62 remotely eitherthrough a cable or wirelessly for production control/quality controlwhile interfacing through a cloud server 72. The software 76, 200 of thesystem transforms and records the data values in records 304 for theindustrial tools 62 (torque, size, etc.) and sends them to the cloudserver 72 where remote supervisors can review, audit and control work.Those production values can be verified by the quality software 76. Inembodiment, the quality control data can be transmitted or received toand from any measurement device that has a digital output. Transmissionto the measurement device may be via wired or wireless channels byattaching a transceiver to the device. In this way, similar qualitycontrol data may be collected from the apparatus under constructiondirectly, for example, from the unit on which lug nuts are beingtightened. For example, very large pipe sections, like those for windturbines, have a tightening spec for the nuts on the flange but also alevelling specification for the flange itself in order to keep themono-pole as straight as possible. The levelling is checked by laser,calliper, etc. Data may be collected and stored with the production datato fully qualify an assembly job.

The various embodiments described above are provided by way ofillustration only, and should not be construed to limit the invention.Those skilled in the art will readily recognize various modificationsand changes that may be made to the claimed invention without followingthe example embodiments and applications illustrated and describedherein, and without departing from the true spirit and scope of theclaimed invention, which is set forth in the following claims.

What is claimed is:
 1. A system for production control, comprising: an electronic device; one or more network connectors associated with the electronic device configured to connect to a server computer, the server computer containing a database of one or more work instructions that are downloadable to the electronic device through the one or more network connectors, the one or more work instructions configured to provide operation instructions for one or more tools; and the one or more network connectors further configured to provide work instructions to the one or more tools.
 2. The system of claim 1, wherein the one or more work instructions are updatable.
 3. The system of claim 1, wherein the electronic device further comprises an input device.
 4. The system of claim 3, wherein the input device is configured to receive input from an operator of the electronic device regarding operational errors experienced during operation of the tool.
 5. The system of claim 4, wherein the received input comprises feedback that is used for updating the work instructions to produce updated work instructions to eliminate the operational errors.
 6. The system of claim 5, wherein the one or more network connectors are configured to transmit the feedback to the server computer for updating the database with the updated work instructions.
 7. The system of claim 5, wherein the updated work instructions includes correction of upper and lower control limits of the tool.
 8. The system of claim 1, wherein each of the one or more network connectors are of a type selected from the group consisting of: a wireless frequency interface (wifi), wireless interface, 2G, 3G, 4G, WMAX, near field communication (NFC), satellite, light emitting diode (LED) and Bluetooth.
 9. The system of claim 1, wherein the electronic device is of a type selected from the group consisting of: a personal mobile communicator, cellular phone, smart phone, tablet, two-in-one device, personal computer, and personal digital communicator.
 10. A method for quality control comprising: connecting an electronic device to a server computer using one or more network connectors associated with the electronic device, the server computer containing a database of one or more work instructions that are downloadable to the electronic device through the one or more network connectors; and according to the one or more work instructions, providing operation instructions for one or more tools.
 11. The method of claim 10, wherein the one or more work instructions are updatable.
 12. The method of claim 10, wherein the electronic device further comprises an input device.
 13. The method of claim 12, wherein the input device is configured to receive input from an operator of the electronic device regarding operational errors experienced during operation of the tool.
 14. The method of claim 13, wherein the received input comprises feedback that is used for updating the work instructions to produce updated work instructions to eliminate the operational errors.
 15. The method of claim 14, wherein the one or more network connectors are configured to transmit the feedback to the server computer for updating the database with the updated work instructions.
 16. The method of claim 15, wherein the updated work instructions includes correction of upper and lower control limits of the tool.
 17. The method of claim 10, wherein each of the one or more network connectors are of a type selected from the group consisting of: a wireless frequency interface (wifi), wireless interface, 2G, 3G, 4G, WMAX, near field communication (NFC), light emitting diode (LED), satellite and Bluetooth.
 18. The method of claim 10, wherein the electronic device is of a type selected from the group consisting of: a personal mobile communicator, cellular phone, smart phone, tablet, two-in-one device, personal computer, and personal digital communicator.
 19. A system for wireless control of a tool, comprising: an electronic device; one or more wireless connectors associated with the electronic device configured to connect to a tool and a the server computer containing a database of one or more work instructions that are downloadable to the electronic device through the one or more network connectors, the one or more work instructions configured to provide operation instructions for the tool; and the one or more network connectors further configured to provide work instructions to the tool.
 20. The system of claim 19, wherein the work instructions include instructions to make sure that the operator of the tool operates the tool through the electronic device within specifications. 